DRAFT FOR SEMINAR Processing of structural composites Aamir

1. Manufacturing process selection techniques/criteria 2. Processing needs 3. Processing techniques per thermoset e thermoplastic Forming Processes for Thermosetting matrix composites: Hand layup and sprayup techniques. Filament winding. Pultrusion. Resin transfer moulding. Autoclave moulding.

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Forming Processes for Thermoplastic matrix composites: Injection moulding. Film stacking. Diaphragm forming. Thermoplastic tape laying.

4. Applications 5. Example of aerospace industry Main parts and the processing techniques used

6. Conclusion

In the RTM process, dry (i.e. non-impregnated ) reinforcement is preshaped and oriented into skeleton of the actual part known as the preform which is inserted into a matched die mold. The heated mold is closed and the liquid resin is injected The part is cured in mold.

The mold is opened and part is removed from mold

Resin Transfer Moulding Close mold low pressure process.

A dry preform is placed in a matched metal die. A vaccum pulls the Low viscosity resin through a flow medium that helps impregnate the preform. Resin may also be forced by means of a pump.

6.1 Introduction
Every material possesses unique physical, mechanical, and processing characteristics and therefore a suitable manufacturing technique must be utilized to transform the material to the final shape. One transforming method may be best suited for one material and may not be an effective choice for another material. For example, wood is very easy to machine and therefore machining is quite heavily utilized for transforming a wooden block to its final shape. Ceramic parts are difficult to machine and therefore are usually made from powder using hot press techniques. In metals, machining of the blank or sheet to the desired shape using a lathe or CNC machine is very common. In metals, standard sizes of blanks, rods, and sheets are machined and then welded or fastened to obtain the final part. In composites, machining of standard-sized sheets or blanks is not common and is avoided because it

cuts the fibers and creates discontinuity in the fibers. Exposed and discontinuous fibers decrease the performance of the composites. Moreover, the ease of composites processing facilitates obtaining near-net-shape parts. Composites do not have high pressure and temperature requirements for part processing as compared to the processing of metal parts using extrusion, roll forming, or casting. Because of this, composite parts are easily transformed to near-net-shape parts using simple and low-cost tooling. In certain applications such as making boat hulls, composite parts are made at room temperature with little pressure. This lower-energy requirement in the processing of composites as compared to metals offers various new opportunities for transforming the raw material to near-net-shape parts. There are two major benefits in producing near-net- or net-shape parts. First, it minimizes the machining requirement and thus the cost of machining. Second, it minimizes the scrap and thus provides material savings. There are cases when machining of the composites is required to make holes or to create special features. The machining of composites requires a different approach than machining of metals; this is discussed in Chapter 10.
2002 by CRC Press LLC

Composite production techniques utilize various types of composite raw materials, including fibers, resins, mats, fabrics, prepregs, and molding compounds, for the fabrication of composite parts. Each manufacturing technique requires different types of material systems, different processing conditions, and different tools for part fabrication. Figure 1.5 in Chapter 1 shows a list of the various types of most commonly used composites manufacturing techniques and Figure 2.1 in Chapter 2 shows the type of raw materials used in those manufacturing techniques. Each technique has its own advantages and disadvantages in terms of processing, part size, part shapes, part cost, etc. Part production success relies on the correct selection of a manufacturing technique as well as judicious selection of processing parameters. The main focus of this chapter is to describe emerging and commercially available manufacturing techniques in the field of thermosetand thermoplastic-based composite materials. Various composites manufacturing techniques are discussed in terms of their limitations, advantages, methods of applying heat and pressure, type of raw materials used, and other important parameters. The basic knowledge of these processes will help in selecting the right process for an application. Section 6.2 briefly describes the manufacturing process selection criteria.

6.2 Manufacturing Process Selection Criteria

It is a monumental challenge for design and manufacturing engineers to select the right manufacturing process for the production of a part, the reason being that design and manufacturing engineers have so many choices in terms of raw materials and processing techniques to fabricate the part. This section briefly discusses the criteria for selecting a process. Selection of a process depends on the application need. The criteria for selecting a process depend on the production rate, cost, strength, and size and shape requirements of the part, as described below. 6.2.1 Production Rate/Speed Depending on the application and market needs, the rate of production is different. For example, the automobile market requires a high rate of production, for example, 10,000 units per year (40 per day) to 5,000,000 per year (20,000 per day). In the aerospace market, production requirements are usually in the range of 10 to 100 per year. Similarly, there are composites manufacturing techniques that are suitable for low-volume and high-volume production environments. For example, hand lay-up and wet lay-up processes cannot be used for high-volume production, whereas compression molding (SMC) and injection molding are used to meet high-volume production needs.
2002 by CRC Press LLC

6.2.2 Cost Most consumer and automobile markets are cost sensitive and cannot afford higher production costs. Factors influencing cost are tooling, labor, raw materials,

process cycle time, and assembly time. There are some composite processing techniques that are good at producing low-cost parts, while others are cost prohibitive. Determining the cost of a product is not an easy task and requires a thorough understanding of cost estimating techniques. The cost of a product is significantly affected by production volume needs as well. For example, compression molding (SMC) is selected over stamping of steel for the fabrication of automotive body panels when the production volume is less than 150,000 per year. For higher volume rates, steel stamping is preferred. Various cost-estimating techniques, as well as various parameters that affect the final cost of the products, are discussed in Chapter 11. 6.2.3 Performance Each composite process utilizes different starting materials and therefore the final properties of the part are different. The strength of the composite part strongly depends on fiber type, fiber length, fiber orientation, and fiber content (60 to 70% is strongest, as a rule). For example, continuous fiber composites provide much higher stiffness and strength than shorter fiber composites. Depending on the application need, a suitable raw material and thus a suitable composite manufacturing technique are selected. 6.2.4 Size The size of the structure is also a deciding factor in screening manufacturing processes. The automobile market typically requires smaller-sized components compared to the aerospace and marine industries. For small- to medium-sized components, closed moldings are preferred; whereas for large structures such as a boat hull, an open molding process is used. Table 6.1 reveals the suitability of composites manufacturing techniques in terms of product size. 6.2.5 Shape The shape of a product also plays a deciding role in the selection of a production technique. For example, filament winding is most suitable for the manufacture of pressure vessels and cylindrical shapes. Pultrusion is very economical in producing long parts with uniform cross-section, such as circular and rectangular. Table 6.1 characterizes each manufacturing method based on the above factors. The cost category of the part is shown when the manufacturing equipment is running at full capacity.